Apparatus and method of constructing a modular floating retaining wall

ABSTRACT

The invention is a floating natural mortared stone modular wall and method for constructing the same. This natural mortared stone modular wall floats and does not require footings. The modular characteristic of the invention allows each segment to float with the frost conditions and allows each wall segment to be moveable. Each wall segment has an extension piece at one end and a slot of larger dimensions than the extension at the other end, thereby allowing the wall segments to fit together and move independently of one another in a vertical motion and each wall segment is capable of being cable anchored on the back. The invention also discloses a method of making the wall segments, whereby sand is washed around and off of the plurality of stones, thereby creating a concrete impervious base upon which to pour reinforced concrete, and a frame is disclosed whereby the poured concrete creates an extension and a slot at opposite ends of the wall segment.

FIELD OF INVENTION

The invention relates generally to a retaining wall system, and more particularly, to a floating modular retaining wall system having a natural stone or rock facade and method of constructing the same.

PRIOR ART

Retaining wall systems are well known, and many varied types are also well known and practiced. Retaining walls of similar type to the present invention are typically made by laying stones or rocks onto a bed of sand within a mold, and pouring concrete over the stones or rocks thereby embedding the stones or rocks in the concrete. The resulting wall face, thus, has a portion of the stone or rock protruding from the concrete block thereby resembling a hand-assembled rock and mortared wall.

Various types of wall panels made in the foregoing manner are disclosed in U.S. Pat. No. 5,624,615—Sandorff; U.S. Pat. No. 3,874,140—Seehusen; U.S. Pat. No. 3,390,496—Weiner et al; U.S. Pat. No. 2,151,420—Carvel; U.S. Pat. No. 1,916,308—Grieco; and U.S. Pat. No. 1,169,985—Mickelson. Other materials have been used instead of sand, such as straw or dried mud (U.S. Pat. No. 2,047,648—Pollard).

In U.S. Pat. No. 5,624,615—Sandorff, a method of manufacturing modular stone panels is disclosed whereby a first stone is placed in a horizontal mold, a layer of sand is then placed within the horizontal mold adjacent to the stone, and the stone is slid through the sand to one of the perimeter walls of the mold, thereby compacting the sand between the stone and the perimeter wall. Additional stones are placed in the sand and slid as well to the perimeter wall or to an adjacent stone, thereby compacting sand between each stones and the perimeter walls and each other.

The prior art is inherently problematic in practice. One problem is that when concrete is poured over the stones or rocks in the bed of sand, the concrete tends to flow through the sand or other removable material resulting in an uneven concrete wall face and, at best, an inconsistent showing of stones or rocks through the concrete. Thus, the aesthetic purpose of such a wall is ruined without further preparation. This problem results from the concrete, which can be quite heavy and dense, infiltrating and/or displacing the sand or bed material thus flowing to and adhering to the front face of the stones or rocks. The concrete can also mix with the sand or other bed material thereby creating an uneven and unappealing face of the wall. Sliding the stones through the sand does not totally alleviate this problem, since the last stone that is set into the bed of sand, when slid, would necessarily create a space void of sand, which would then need to be filled in with sand, which would result in the same types of problems as described above, especially in the area surrounding the last stone placed into the mold. Further, sliding the stones results in an uneven layer of sand between the stones and between the wall of the form and the stones.

Another problem is how to prevent the wall segment from cracking under normal or uneven settling conditions, or, if used in northern climates, how to prevent cracking under normal freezing and thawing conditions.

Other problems include how to easily join one or more of the modular wall segments without adding to the problem described above, that of the wall cracking during settling and under freezing and thawing conditions, or of the joined wall segments cracking at the point of joining.

Other problems include how to form a corner with the wall segments so that the aesthetic function of the wall is not diminished.

Still further problems include anchoring the wall segments to the back-filled earth while still allowing for some movement to prevent the breaking or cracking due to ground settling, and the freezing and thawing cycles of northern climates.

The present invention is directed towards overcoming these problems.

DISCLOSURE OF THE INVENTION

According to the invention, a modular, floating stone wall segment and method of constructing the same are provided comprising a front face, a top, a bottom, a slot end side, an extension piece side, a back, and a plurality of stones or rocks embedded in reinforced concrete such that the front face has the appearance of a stone masonry wall. Mortar and joint grout may be applied to the front face between the stones to enhance the hand-laid appearance of the stone wall. In another embodiment, the reinforced concrete is poured over the stones or rocks such that a portion of each stone or rock protrudes from the back face, thus both sides of the wall segment have the appearance of a hand-laid masonry stone wall. Of course, the mortar and joint grout may then placed between the stones or rocks on the back face as well.

A slot end side comprises a slot extending from the top to the bottom of the wall segment, and an extension piece end side comprises an extension piece also extending from the top to the bottom of the wall segment, wherein the extension piece would fit within the slot, thereby allowing the wall segments to slide together, further allowing the wall segments to move freely up and down in relation to one another. The slot has a width and depth greater than the width and depth of the extension piece, thereby also allowing the wall segments to be fitted together at a slight angle to each other. The specific dimensions of the slot width and depth and the extension piece width and depth would vary depending upon the overall dimensions of the wall segment. The importance of the dimensions are, of course, that the extension piece be thinner and of shorter depth than the slot width and depth, thereby creating sufficient space to allow the two respective wall segments to move independently of one another in a vertical motion. The space created also allows the respective wall segments to be angled together in a non-linear configuration, while still being somewhat coupled together.

In the preferred embodiment, a five-sided rectangular box shaped form is used, being made of steel or wood or some other durable, form-retaining material, being comprised of a bottom frame, a top frame, an extension piece end frame, a slot end frame, the bottom, top, slot end and extension piece frames being removably and sturdily attached together to form a rectangular form, the top and bottom frames opposite each other and the slot end and extension piece frames opposite each other, and a front face frame, the front face frame being a solid sheet of steel, wood or some other like material attached to the rectangular form thereby creating a box shaped form. A plurality of stones or rocks are placed on the front face frame of the form, sand is spread evenly over the stones or rocks, thereby sifting down to the open spaces between the stones or rocks, and the sand and stones or rocks are then washed down with water, thereby allowing the sand to filter into the void spaces between and under the stone or rock edges, and thus creating an even layer of sand in the form. Additional sand may be applied and washed down to ensure an even layer of sand in the form.

Two lift rings are disposed on the top side, preferably each in a recess such that each lifting ring is firmly embedded in the reinforced concrete and does not protrude above the face of the top side. Other embodiments would show one or more lift rings, depending upon the length and overall size of the wall segment. The modular wall segment can be made any size or length. A small modular wall segment may only need one lift ring, while a large modular wall segment may require more than two lift rings.

An anchor cable is situated such that it extends out the back of the wall segment. A reinforced concrete is then poured over the stones or rocks, thus creating a reinforced concrete wall segment with two lifting rings on the top of the wall segment, a natural looking stone or rock appearance on the front face of the wall segment, and an anchor cable extending out the back of the wall segment. An anchor rod comprising a rod loop hook end, a metal rod and an auger end is disclosed, said loop hook end of said anchor rod being hooked to the anchor cable and the metal rod and auger end are embedded into the earth behind the wall segment.

A further embodiment shows the wall segments set on a base of compacted crushed gravel, preferably class-5 aggregate, the thickness of the aggregate depending upon the height of the wall segment, and an area immediately behind the wall segment being filled with 1½ inch drainage rock and drain tile.

Another embodiment shows one or both of the slot end or extension piece end sides to be angled such that the wall segments, when placed together, would form a corner.

It will be appreciated that an advantage of this invention is that the modular wall segments could be manufactured year round in a manufacturing facility and transported to the site during construction season.

Further advantages include the ability to manufacture the wall segments in a variety of lengths and angled configurations, as well as column shaped segments for placement between or at the end of the preferred embodiment wall segments.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of the front of the modular wall segment.

FIG. 2 is a perspective view of the back of the modular wall segment.

FIGS. 3A and 3B show the in-side and top views of the extension piece end frame, respectively.

FIGS. 4A and 4B show the in-side and top views of the slot end frame, respectively.

FIG. 5 is a perspective view of the modular wall segment frame.

DETAILED DESCRIPTION OF DRAWINGS AND BEST MODE FOR CARRYING OUT THE INVENTION

Referring now to the drawings wherein like reference numerals designate identical or corresponding parts throughout the several views, FIG. 1 shows the preferred embodiment of the modular wall segment 1, comprising a front face 2, a back 3, a top 4, a bottom 5, a slot 6, a slot end side 7, an extension piece 8, an extension piece end side 9, and a plurality of stones 10 or rocks embedded in reinforced concrete such that the front face 2 has the appearance of a stone masonry wall. The top comprises two lift rings 11 fixedly embedded within the modular wall segment and protruding from the top 4.

In practice, multiple segments of the modular wall can be fit together, the extension piece end side 9 of one segment fitting into the slot end side 7 of another, thereby fitting together multiple segments into an a near seamless wall.

Referring now to FIG. 2, a perspective view of the modular wall segment is shown comprising a back 3, the back 3 comprising a plurality of anchor cables 12 fixedly embedded within back 3 of the modular wall segment. The anchor cable 12 comprises a loop portion 13 and an embedded portion 14, the embedded portion 14 is fixedly embedded in the reinforced concrete mixture and the loop portion 13 protrudes out from the reinforced concrete mixture. The anchor cables 12 are thus able to be attached to an anchor rod wherein the modular wall segment can be anchored into the earth. There can be many variations of the anchor rod however; the preferred embodiment would show the anchor rod comprising a loop hook end, a metal rod and an auger end, the loop hook end of said anchor rod being attached to the anchor cables loop portion 13. Thus, the two loop ends of the respective anchor cable and anchor rod would be able to move and slide independent of one another. This is advantageous since any slight movement of the earth behind the wall segment may move the anchor rod but will not move the anchor cable or the wall, thus reducing the likelihood of the wall cracking or enduring undue stress. Referring to FIG. 2, the slot end side 7 is shown, as is the extension piece end side 9.

Referring to FIGS. 3A and 3B, the extension piece end frame 15 for making the modular wall segment is shown. FIG. 3A shows an in-side view of the extension piece end frame 15 and FIG. 3B shows an end view of the extension piece end frame 15. The extension piece end frame 15 makes the slot end 7 of the modular wall segment and forms the slot 6.

Referring now to FIGS. 4A and 4B, the slot end frame 16 for making the modular wall segment is shown. FIG. 4A shows an in-side view of the slot end frame 16 and FIG. 4B shows an end view of the slot end frame 16. The slot end frame 16 makes the extension piece end 9 of the modular wall segment and forms the extension piece 8.

The dimensions of extension piece end frame are such that the slot formed is of a greater dimension in both width and depth than the width and depth dimensions of the extension piece formed by the slot end frame, thus allowing the extension piece to move within the slot. The slot can be made slightly larger than the extension, as in the preferred embodiment, or more so, to facilitate greater movement of the two respective wall segments. This movement allows the wall segments to be placed in a non-linear configuration, such as at an angle to one another, either a slight angle or a more defined angle.

Referring to FIG. 5, a perspective view of the modular wall segment frame 17 is shown. The extension piece end frame 15 and slot end frame 16 are shown, being removably attached to a top frame 18 and a bottom frame 19. A front face frame 20 is also disclosed, being removably attached to the top frame 18, bottom frame 19, extension piece end frame 15 and slot end frame 16, thereby forming an inner bottom surface 21 of the frame, whereby a plurality of stones are placed within the modular wall segment frame, resting on the inner bottom surface 21, and sand is placed or shoveled over the stones to a sufficient depth. The sand is then washed off the stones with water thus ensuring that all of the tops of the stones are free of sand and further ensuring the sand becomes evenly packed between each stone and between the stones and the modular wall segment frame and evenly packed onto the inner bottom surface. Reinforced concrete is then poured between and over the stones, and between the stones and the modular wall segment frame until the reinforced concrete covers the stones and the entire sanded area within the modular wall segment frame. The sand thus forms a layer through which the reinforced concrete cannot flow. Once the reinforced concrete has cured to a sufficient strength, the front face frame, the top frame, bottom frame, the extension piece end frame and the slot end frame are removed from the wall segment. Excess sand is removed from the front face of the wall segment, and mortar and joint are applied between the stones to allow for an attractive stone wall appearance. When a plurality of wall segments are placed together in a finished stone retaining wall product, mortar and joint may be applied carefully to the respective edges of each wall segment to blend each wall segment into each other, thus having the appearance of a solid stone wall unit.

Referring once again to FIG. 2, the anchor cables 12 are shown recessed into the reinforced concrete of the modular wall segment. A further embodiment would show the anchor cables 12 protruding from the reinforced concrete. FIG. 2 further discloses the lift rings 11 recessed into the top 4 of the wall segment 1. The recessed lift rings 11 can be placed anywhere on the top portion of the wall segment, however, for purposes of balance when lifting the wall segment, the lift rings should be placed within recesses such that the weight of the wall segment is evenly distributed to each lift ring. A further embodiment would disclose each lift ring in a recess, each such recess being a notch in the edge delineating the corner between the top and the back of the wall, thus, in effect, being a recess in both the top of the wall and in the back of the wall. Another embodiment would have the lift rings protruding from the top of the wall segment; however, the recessed feature creates a flatter top surface, thus allowing for a more stable placement of a functional or decorative cap or header on top of the wall segment.

The finished modular wall segment would be placed upon a level base comprised of crushed rock. Each modular wall segment would fit together, the extension piece end sliding into the slot end, thereby allowing each wall segment to independently move up and down. The advantage of the ability to slide up and down, while remaining connected, allows for each wall segment to move slightly in the event the ground moves, such as when a frost or freezing of the ground occurs, which may vary under or around each wall segment. A solid wall would crack or weaken due to the stress of such ground movement. The present invention is less likely to crack, if at all.

The finished wall segment would also be anchored to the earth behind the wall segment through the use of the anchor cables and anchor rods. The recessed anchor cables being connected to the loop end of the anchor rod, also allows for some movement of the anchor rod in the event the earth behind the wall segment moves, thereby greatly reducing the likelihood of the wall segment moving in the event of minor earth movement behind the wall segment.

A functional or decorative cap can be placed upon the modular wall segment to complete its appearance as an attractive stone retaining wall. 

1. A modular, floating stone wall segment comprising a plurality of stones embedded in a reinforced concrete mixture, a front face wherein the front face comprises the plurality of stones protruding from the reinforced concrete mixture wherein the front face has the appearance of a stone masonry wall, a back, a top comprising a lift ring fixedly embedded within the reinforced concrete mixture, a bottom, a slot end side comprising a slot extending along the slot end side from the top to the bottom of the wall segment, and an extension piece end side comprising an extension piece extending along the extension piece end side from the top to the bottom of the wall segment, whereby the slot end side of one wall segment can fit together with the extension piece end side of another wall segment, thereby allowing each wall segment to form a near seamless stone masonry wall and move upward and downward independently of each other.
 2. The modular, floating wall segment of claim 1 wherein the top comprises a plurality of lift rings.
 3. The modular, floating wall segment of claim 1 wherein the lift ring is fixedly embedded within a recess in the reinforced concrete mixture, whereby the lift ring does not protrude above the top of the wall segment.
 4. The modular, floating wall segment of claim 1 wherein the back comprises an anchor cable fixedly embedded within the reinforced concrete mixture.
 5. The modular, floating wall segment of claim 4 wherein the back comprises a plurality of anchor cables.
 6. The modular, floating wall segment of claim 4 wherein the anchor cable is fixedly embedded within a recess in the reinforced concrete mixture.
 7. The modular, floating wall segment of claim 4 wherein the anchor cable comprises a loop portion and an embedded portion, said embedded portion being fixedly embedded in the reinforced concrete mixture and said loop portion protruding out from the reinforced concrete mixture.
 8. The modular, floating wall segment of claim 7 wherein the loop portion of the anchor cable attaches to an anchor rod, said anchor rod comprising a rod loop hook end, a metal rod, and an auger end, whereby the anchor cable loop portion is attached to the anchor rod loop hook end, and the metal rod and auger end extend into the earth behind the wall segment, whereby the anchor cable and the anchor rod can move independently of one another.
 9. The modular, floating wall segment of claim 1 wherein the slot comprises a certain slot depth and a certain slot width, and wherein the extension piece comprises a certain extension depth and a certain extension width, the slot depth being larger than the extension depth and the slot width being larger than the extension width, thereby allowing the extension piece to move within the slot, whereby two connected wall segments may move independently of one another.
 10. The modular, floating wall segment of claim 9 wherein the slot depth and slot width are sufficiently larger than the extension depth and extension width whereby connected wall segments can be arranged in a non-linear, angled configuration.
 11. The modular, floating wall segment of claim 1 wherein the plurality of stones protrude from the back of said modular, floating wall segment wherein the back has the appearance of a stone masonry wall.
 12. A method of constructing a modular, floating wall segment comprising a modular wall segment frame, a plurality of stones, sand, water, reinforced concrete, mortar and joint grout, said modular wall segment frame comprising an extension piece end frame, a slot end-frame, a top frame, a bottom frame, and a front face frame, said extension piece end frame, slot end frame, top frame and bottom frame being removably attached to each other to form the shape of a rectangular frame, having the top frame and bottom frame opposite each other, and the extension piece end frame and slot end frame opposite each other, said front face frame being removably attached to the rectangular frame, thereby forming an inner bottom surface of the wall segment frame, said plurality of stones are placed within the modular wall segment frame, resting on the inner bottom surface, and the sand is placed over the stones to a sufficient depth, the sand is then washed off the stones with the water thus ensuring that no sand rests upon the stones, the sand thus becoming evenly packed between each stone and between the stones and the modular wall segment frame and evenly packed onto the inner bottom surface, said reinforced concrete is then poured between and over the stones, and between the stones and the modular wall segment frame until the reinforced concrete covers the stones and the entire sanded area within the modular wall segment frame, whereby the sand thus forms a layer through which the reinforced concrete cannot flow, thus forming a front face of the modular, floating wall segment, said reinforced concrete is allowed to cure to a sufficient strength, whereby the front face frame, the top frame, bottom frame, the extension piece end frame and the slot end frame are removed from the wall segment, excess sand is removed from the front face of the wall segment, mortar and joint grout are applied between the stones thereby providing for an attractive stone wall appearance.
 13. The method of claim 12 wherein the extension piece end frame comprises a length, a midline along the length and a protruding rib at the midline and along the length, whereby the reinforced concrete would flow around the protruding rib, thereby creating a slot along the length of the extension piece end frame, and wherein the slot end frame comprises a length, a midline along the length and a recessed furrow at the midline and along the length, whereby the reinforced concrete would flow into the recessed furrow, thereby creating an extension piece along the length of the slot end frame.
 14. The method of claim 13 further comprising a plurality of wall segments being placed together in a finished stone retaining wall product, said mortar and joint grout being applied between each wall segment to blend each wall segment into each other, thus having the appearance of a solid stone wall unit.
 15. The method of claim 13 further comprising a base of compacted crushed gravel whereby the modular, floating wall segment is placed upon the compacted crushed gravel, the thickness of the gravel depending upon the height of the wall segment, and further comprising an area immediately behind the wall segment being filled with 1½ inch drainage rock and drain tile.
 16. The method of claim 15 wherein the crushed gravel comprises class-5 aggregate.
 17. A method of constructing a modular, floating wall segment comprising a modular wall segment frame, a plurality of stones, sand, water, reinforced concrete, mortar and joint grout, said modular wall segment frame comprising an extension piece end frame, a slot end frame, a top frame, a bottom frame, and a front face frame, said extension piece end frame, slot end frame, top frame and bottom frame being removably attached to each other to form the shape of a rectangular frame, having the top frame and bottom frame opposite each other, and the extension piece end frame and slot end frame opposite each other, said front face frame being removably attached to the rectangular frame, thereby forming an inner bottom surface of the wall segment frame, said plurality of stones are placed within the modular wall segment frame, resting on the inner bottom surface, and the sand is placed over the stones to a sufficient depth, the sand is then washed off the stones with the water thus ensuring that no sand rests upon the stones, the sand thus becoming evenly packed between each stone and between the stones and the modular wall segment frame and evenly packed onto the inner bottom surface, said reinforced concrete is then poured between the stones, and between the stones and the modular wall segment frame until the reinforced concrete surrounds the stones and the entire sanded area within the modular wall segment frame, whereby the stones protrude above the reinforced concrete thus forming a back face of the modular, floating wall, and the sand thus forms a layer through which the reinforced concrete cannot flow, thus forming a front face of the modular, floating wall segment, said reinforced concrete is allowed to cure to a sufficient strength, whereby the front face frame, the top frame, bottom frame, the extension piece end frame and the slot end frame are removed from the wall segment, excess sand is removed from the front face of the wall segment, mortar and joint grout are applied between the stones on the front face and the back face of the wall segment thereby providing for an attractive stone wall appearance.
 18. The method of claim 17 wherein the extension piece end frame comprises a length, a midline along the length and a protruding rib at the midline and along the length, whereby the reinforced concrete would flow around the protruding rib, thereby creating a slot along the length of the extension piece end frame, and wherein the slot end frame comprises a length, a midline along the length and a recessed furrow at the midline and along the length, whereby the reinforced concrete would flow into the recessed furrow, thereby creating an extension piece along the length of the slot end frame.
 19. The method of claim 18 further comprising a plurality of wall segments being placed together in a finished stone retaining wall product, said mortar and joint grout being applied between each wall segment to blend each wall segment into each other, thus having the appearance of a solid stone wall unit.
 20. The method of claim 18 further comprising a base of compacted crushed gravel whereby the modular, floating wall segment is placed upon the compacted crushed gravel, the thickness of the gravel depending upon the height of the wall segment, and further comprising an area immediately behind the wall segment being filled with 1½ inch drainage rock and drain tile.
 21. The method of claim 20 wherein the crushed gravel comprises class-5 aggregate. 